Welding rod



Aug. 23, 1932. I s. w. MILLER 4 1,873,847

WELDING ROD Filed Feb. 6, 1928 Patented Aug. 23, 1932 mmfswas PATENrTorrIcEf I solid metal for the K'w 'nmmenon a mum" was, a, 1m. sum lb. $52,314.

This invention relates to im roven ents in metallic wel'din rods, adapted tobe fused by means'of a igh temperature gas flame or an electric arc and deposited unheated purpose. of welding, fillenerally speaking, the thickness of the work being welded by a. gasflame, such as an oxy-acet lene flame, determines the size of the welding flame which should'be employed, although practical difliculties are en.

, countered in designin very lar elwelding nozzles or headslfor we ding very hick work,

so there is a practical limit to the size of the 15 welding flame. which mayQbepmduced. [It

has been customary toLusea sin le round metallic rod for we ding purposes, at welding rods of very lar'gediameter areseldom carried in stock or used for welding,no so matter'how thick the work may be or what the size of the lflame may.be.- orexample,

the usual rod for welding steel of all thicknesses from one-half inch up isone-quarter inch in diameter. Considerable heat isthere-. 2 fore wasted-andprogress is slow when the usual single round wire is used with larger flames for welding the thickerwork. For heavy steel welding, whejrea large flame is required to keep the work properly heated,

to two one-quarter inch rods have been secured together parallel .to' each other by. binding wires. The objection to this wiring together is that the welder almost always bends'the rods at some point about nine inches from the work to: avoid .the strain of holding straight rods nearly vertical'to the work and to keep his hand holdingtherods from the heat. This bending of the two wired-together rods causes the ends that are being meltedofi to separate, resulting in delays and dim culties in manipulating the rods. I

The principal object of this invention is to provide an improved welding rodwhereby weld metalmay be more rapidly and economically deposited than in the use of the common welding rod of circularcross-section, especially whenwelding metal of considerable thickness or when filling large cav.-'

ities. Another object is to provide a welding thereto, an one which prefers lyis thicker intermediate its lateral edges than ad'acent such edges, wheres (1) les as or e ectric current is consum .per poun of metal. de-

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posited, (2) theseat of the welding flame may be confined and moreffull utilized, (3)v the hottest part of the welding flame maybe applied to the thickest part of the rodyand (4) welding may be facilitated by turning the rodabout its central longitudinal axis as occasion demands to present either thenarrow or the wider side of the rod to the V-shaped oove, between the bevelled ed softhe wor tobewelded. e e

e above and other. objectsand the novel features of this invention will be apparent from the following description and the aocoil npanying drawing, in which 1gs.1 to 8 inclusive are cross-sectional views of metallic welding rods embodying.

various features of this invention;

Fig. .9 1s a invention; and

Figs. 10 and 11 are sectional views dia grammatically illustrating positions of my preferred. type'of welding rod at different rspective view of a referredform of meta lic, welding rod embo ying this stages when weldin g together two thick plates havi "opposed bevelled edges.v

As havealready stated, certainobjections are encountered in welding with two rods wired together. When such rods are bent to provide a handle 'whereby the welder may conveniently holdthem at the desiredinclina I permanently unite in parallelcontacting relation two or more rods of the same length,

as shown in Figs. 1 to 4 inclusive. The per-.

manent unions between the several parallel rods may consistof. spot welds at shortintervals apart, say. two. inches, throughout their length; or a continuous "longitudinal; joint between the parallel rods may be produced by electric resistance welding. Two or more welding rods permanently joined together in this way ma be bent as desired and will stay together. s shown in Fig. 1 the rods and 16 are permanently united by a longitudinal joint 17; in Fig. 2, the rods 18, 19, 20 are permanently united into a unitary welding rod by longitudinal joints 21 and 22; in Fig. 3 the rods 23, 24 and 25 are arranged with their longitudinal axes atthe apexesof a triangle and are permanently united into a unitary rod by longitudinal joints 26,27 and 28; while the rods 29, 30, 31, 32, forming the unitary welding rod shown in Fig. 4, are

united by longitudinal joints 33, 34 and35. In all instances, the joints may be either spot welds or continuous resistance welds, and if desired, the spaces on opposite sides of the joints throughout the length of the composite rods may befilled with suitable flu'xin material level with planes tangent to' ad oining rods, as indicated at 36 in Figs. 2 and 4 for example. Similarly, suitable flux may be introduced into the space between the rods of Fig. 3, as indicated at 37, with or without flux in the outer V-shaped s aces adjacent the joints 26, 27 and 28. The ux is thus carried by and distributed throughout the length of the composite rod and is automatically supplied to the weld as required.

More or less oxide and slag may be produced at the weld-junctions between the rods shown in Figs. 1 to 4 inclusive which is objectionable in some instances because such oxide or slag may get into the weld metal that is deposited from the rod. To overcome this, I provide a unitary double welding rod which may be drawn or otherwise formed to have a cross-section somewhat similar to that of a dumb-bell, as shown at38 in Fig. 6. If desired, flux 39 may be applied lengthwise of and to opposite sides of the web between the lobes of the rod 38.

. melting the rod nor sufficient to keep the base metal in a state of fusion to receive the melted rod deposited thereon. By presenting my improved composite rod to the work in such a manner that its broad side faces the weld, more of the flame and heat are confined between the rod and the weld and reflected back to the work and weld,'so that heat otherwise wasted may be utilized for melting the rod and keeping the weld and base metal at a fusion temperature, resulting in faster welding and ter economy. Moreover, by turning this type of rod so as to present its narrow side to the bottom of the V-groove, the welder may get to the bottom of the groove as easily as with a single round rod.

In some welding operations I find it advantageous to provide the welding rod with a concave lower face which serves to confine the heat better than a flat broad face. In Fig. 4, for example, the several rods 29, 30, 31 and 32 are permanently united so their longitudinal axes and the weld unions lie on a curve, whereby one side of the composite od is concave throughout its len h. Another type of weldin rod embo ying this feature is shown in 1g. 5, wherein the rod 40 consists of a substantially rectangular metal strip rolled, bent or otherwise grooved so as to form a concave side 40', extending lengthwise of the rod.

Inasmuch as the intensity of the heat of the oxy-acetylene welding flame is greatest at the point of the central white cone, I have found that the ideal cross-sectional shape of welding rod for general purposes is one which has one cross-sectional dimension substantially greater than the other, and a portion intermediate the lateral edges substantially thicker than the portions along such lateral edges. Hence, in welding, the thicker part of the rod will be the part which is subjected to the heat almost continuously and is usuall opposite the intensest part of the flame. igs. 8 and 9 illustrate improved welding rods embodying these features of my invention. The section of the welding rod 41, as shown in Fig. 8, is in a plane perpendicular to the longitudinal axis of the rod, and is in the form of a parallelogram, two opposite angles of which are acute, the diagonal 42 joining their apex being the longest dimension of the section of the rod. The thickest section of the rod as used is along its diagonal 43, and the rod is so formed that every short diagonal at all other cross-sections of the rod is in the same plane with the diagonal 43, while every long transverse diagonal' along the rod is in the same plane with the diagonal 42.

The metallic welding rod 44 shown in Fig. 9 is the referred form. A section taken perpendicu ar to this rod at any point lengthwise of its axis is an ellipse, the major and minor axes 45 and 46 of which res ectivel measure the width and thickness 0 the r0 The major axes of all elliptical sections of the rod lie in the same plane, and a plane throu h the longitudinal axis of the rod 44 and tirough the minor axis 46 includes all other minor axes.

Figs. 10' and 11 diagrammatically illustrate a welding operation wherein the use of my improved rod is particularly advantageous. Two relatively thick metal plates A and B, to be welded together, are bevelled as... a 3* i as usual along their opposed edges to form a V-shaped groove G to receive the weld metal deposited by the rod 44', for example. To properly weld at the bottom of the V it is important to get the rod close to such bottom, which may be done by turning the rod so that its long dimension is parallel to the height of the V, as shown in Fig. 10. After considerable weld metal has been filledainto the groove, the width of the top surface of the weld is much greater and at the to of the groove with a bevel such widt is twice the thickness of the plate. With an ordinary rod, as already explained, it is necessary to work first on one side of the weld and then on the other, considerable heat is wasted, and it is diflicult to keep the weld and adjoining plate edges in a fused state for proper welding. By simply turning my improved rod 90 about its longitudinal axis so that its wider side faces the weld, a greater width of the weld is covered b the rod,

it is not necessary to move: the r so much from side to side over the weld, the confined.

and reflected heat will be sufiicient to keep the weld metal in a molten condition, and the bevelled faces of the plates may be more easily kept at a welding temperature without overheating the lates back from the edges. The results 0 tests conducted with my improved welding rod clearly show that the amount of welding ases or current used is considerably reduced y thus utilizing heat otherwise wasted, and the amount of metal deposited in a given time is considerably increased.

For many purposes I have also found that a weldin rod of oval cross-section, as shown at 47 in ig. 7, is well adapted for welding and afiords the advantages already set forth. The major and minor axes 48 and 49 are, respectively, in the same plane with the corresponding axes of all perpendicular crosssections of the rod 47, as in the elliptical rod for example, so that as these rods are melted down their broader sides or narrower sides,-

as the case may be, will always be in the same position relatively to the weld and the flame from the welding blowpipe. It will be obvious that the rods 41 and 47 as well as other rods herein shown may used in the manner illustrated in Figs. 10 and 11.

While it is desirable in most instances that the plurality of integrally united rods shown in Figs. 1 to 4 shall have the same metallic composition, I may unite ,rods of different composition in the same manner to provide a composite rod that will deposit weld metal of a composition that differs from any of the ingividual rods which'make up the unitary ro For convenience, I may herein designate the width dimension taken perpendicular to the longitudinal axis of the rod as the major sectional axis of the rod, and the thickness dimensionas the minor sectional axis.

a I claim: 7

LA welding rod composed of a homogeneous elongated. body of metal in which the width dimension taken perpendicular to the longitudinal axis of the rod is substantially greater than the thickness dimension taken perpendicular to such width, said rod havin -a portion intermediate its opposite .latera edges which is thicker than the portions adjoiningsuch edges.

2. A welding rod substantially dumb-bell shape in transverse cross-section.

3. A welding rodhaving a transverse cross-section which is substantially aparal- ,lelogram atevery point lengthwise of the rod, the major axis of said section being. substantially greater than the minor axis,

and all ma or and minor axes lying in the same planes, respectively.

4. welding rod comprising a homogeneous elongated body of metal in which a and the ma or axes of all sections are in the same longitudinal plane through the longitudinal axis of therod.

I 6. A weldin rod comprising a homogeneous elon ted body of metal m'which the sections ta en perpendicular tothe lon itudinal axis are substantially elliptica in shape. e

7. A weldin rod comprising a homogeneous elo atefi body of metal in which the sections ta en perpendicular to the longitudinal axis are figures having unequal axes of symmetry which will coincide with the axes of symmetry of a circumscribed rectan le, the volumeof metal in a given length of t e rod being less than the volume of an equal length of said'rectangular rod.

8. A welding rod comprising a homogeneous elongated body of metal having two curved relatively wide opposing faces and two curved relatively narrow opposing faces, the wide faces being outwardly convex with respect to a plane passin through the longitudinal axls of the ro and parallel to a lane which is tangent to one of the wide by the major axis and the longitudinal axis. 10. A welding rod comprising a homogeneous elongated body of metal m which the sections perpendicular to the longitudinal- 8 axis are figures having major and mlnor axes of unequal length, at least one of the surfaces WhICh terminates the minor axis being bulged outwardly with respect to the plane determined by the major axis and the longi- 10 tudinal axis.

11. Aweldin rod composed of a homogeneous elongated body of metal in which the width dimension taken perpendicular to the longitudinal axis of the rod is substantially greater than the thickness dimension taken perpendicular to such width and in which one of the wider faces of said rod is grooved or concave throughout the length of the rod.

12. A welding rod composed of a homogeneous elongated body of metal in which the width dimension taken perpendicular to the longitudinal axis of the rod is substantially greater than the thickness dimension taken perpendicular to such width and in which a recess extends lengthwise of said rod, said recess containing flux.

In testimony whereof I afiix my signature.

SAMUEL W. MILLER. 

